Rayco 1620, 1625, 1631 & 1635 Upgrade Wheel Assembly .pdf©2015 Green Manufacturing, Inc. 1 Read...

©2015 Green Manufacturing, Inc. 1

Rayco 1620, 1625, 1631 &

1635 Upgrade Wheel

Assembly

If you have any questions or concerns, please call 1-800-473-3683

BEFORE YOU BEGIN

Read these instructions completely and

carefully

Note to installer – Be sure to leave

these instructions for the consumer’s use

Note to consumer – Keep these

instructions with your Owner’s Manual for

future reference

Skill level – Installation of the wheel

requires intermediate mechanical skills.

Proper installation is the responsibility of the

installer. Product failure due to improper

installation is not covered under any

warranty

IMPORTANT - Before you continue,

please check the packing list to make sure it

matches the contents of the boxes.

Disconnect Power

to machine to prevent any machine

components from moving before proceeding.

Failure to do so could result in death or

serious injury.

FOR YOUR SAFETY read and

observe all CAUTIONS and

WARNINGS shown throughout

these instructions. While

performing the installations that

are described in this booklet, gloves

& safety glasses or goggles should

be worn at all times.


Installation Preparation

Green Manufacturing, Inc.

9650 Packard Rd

Morenci, MI 49256

Phone 800.473.3683 • Fax 517.458.1550

TOOLS SUPPLIED:

½” Drive, ½” 6pt Impact Allen Wrench Socket

TORQUE SETTINGS:

900 Series Nut: 35ft. lbs. (47Nm)

LoPro™ Bolt (lubricated with Green-Seize™): 180 to 200ft. lbs. (244 Nm)

TOOLS YOU WILL NEED:

5/8” Socket Wrench

½” Drive Torque Wrench

Green-Seize™

MANUFACTURER’S PARTS LIST:

Part Number Description

926-WS2 900 Series Wearsharp™ 2-Sided Tooth, For Wheels 22" & Smaller

900LP-A 900 Series LoPro™ Pocket - Angle

LP-200 2” LoPro™ Bolt

RAYCO-BELT 2 Banded V-Belt

RAYCO-SHEAVE 2 Grooved Sheave

RAYCO-GUARD Wheel Chip Guard


Table of Contents

Disassembly Instructions ................................................................... 4

Assembly Instructions ........................................................................ 8

Upgrade Assembly Diagram ..............................................................11 Split Taper Bushing Removal & Installation Instructions ...................12 Greenteeth® Guarantee....................................................................13 Material Safety Data Sheet …………………………………………………………….14


Disassembly Instructions

1. If you are not installing the belt and sheave upgrade, proceed to step 9 in the assembly instructions on page 9.

2. Remove clutch assembly guard bolts and remove cover. (Figure 1.1)

3. Remove initial drive cover bolts and remove cover. (Figure 1.2)

Figure 1.1

Figure 1.2


4. Remove final drive bolts and remove cover. (Figure 1.3)

5. Loosen four (4) motor mount bolts. Back the motor mount adjustment bolt off approximately 1”. (Figure 1.4)

6. Slide engine towards cutter wheel to loosen initial drive belt.

Figure 1.3

Figure 1.4


7. Loosen & remove the 15/16” shaft bolt in the center of clutch. It may take several taps to initially loosen the bolt. Remove clutch assembly and set off to the side. (Figure 1.5)

8. Remove initial drive belt. Set it off to the side. It will be replaced with the new belt included in your performance upgrade kit.

9. Measure from back of initial drive cover to front of jack shaft sheave. Record this measurement here, as you will need it for reassembly. (Figure 1.6)

Figure 1.5

Figure 1.6

Sheave Measurement Notes:


10. Remove jackshaft sheave. Follow bushing removal instructions found on page 12. (Figure 1.7 & 1.8)

Figure 1.7

Figure 1.8


Assembly Instructions

1. Subtract ½” from the previously recorded measurement in step 8 of disassembly instructions. Install the new sheave with the manufacturer’s bushing to this measurement. Remember to clean the jackshaft and bushing to ensure smooth installation. Follow bushing installation instructions on page 12. (Figure 1.9)

2. Install the new belt included with your upgrade setup.

3. Reinstall clutch assembly. Belt tension will be set later on in the instructions.

4. Tighten engine mount tensioner checking periodically to ensure proper tension to initial drive belt.

5. Once proper tension to the initial drive belt is achieved, tighten motor mount nuts and bolts. (Figure 1.10)

Figure 1.9

Figure 1.10


6. Reinstall initial drive cover.

7. Reinstall clutch assembly cover.

8. Reconnect power to machine.

9. Locate the pocket set with straight pockets on your wheel. This should be the pocket set extending the furthest away from the center of the wheel. Make sure to refer to the Upgrade Assembly Diagram found on page 11 for the next 12 steps.

10. Remove one set of straight pockets (Notice you will be replacing this set of straight pockets with a set of angle pockets with the upgrade set up).

11. Clean both sides where the pockets contact the wheel, with a wire brush. Be sure to remove all dirt and debris so the pocket is seated tightly against the wheel.

12. Apply Green-Seize™ to the threaded end of two LoPro™ bolts.

13. Starting with the angle pocket install a LoPro™ bolt into the counter-bored hole and then do the same of adjacent pocket of that set.

14. Slide the LoPro™ bolts through the empty holes in the wheel and thread them into the adjacent pocket’s threaded holes. For now, firm up the LoPro™ bolts until pockets are seated. (Figure 1.11)

15. Proceed to the pocket set below the new pocket set installed in step 14. This should be an angle pocket set.

16. Remove the one set of angle pockets (Notice you will be leaving this area blank).

17. Proceed to the pocket set below the removed pocket set in step 16. This should be an angle pocket set.

18. Remove the one set of angle pockets (Notice you will be leaving this area blank).

19. Proceed to the pocket set below the removed pocket set in step 18. This should be an angle pocket set.

20. Repeat steps 9 thru 19 for the next two groups of three pocket sets on the machine.

Figure 1.11


21. Install your teeth with the carbide facing down. The shoulder of the tooth will meet the flat indent of the pocket and the tooth will not rotate. Insert spacer over shank Chamfer down then thread one of the lock nuts onto the top portion of the tooth. Hand tightening is good for now. Repeat until all teeth are installed. (Figure 1.12)

22. Make sure the pockets are seated on the wheel and the bolts are seated in the pockets. Continue tightening your LoPro™ bolts until they are all torqued to 180-200 foot lbs. (244 Nm).

23. Before torqueing your tooth down, first make sure that the tooth is seated properly in the pocket. Then tighten the top nut until the tooth is firmly seated and torqued to 35 ft. lbs. (47 Nm). You may need to hold the tooth in place. Repeat until all teeth are properly torqued.

Over-tightening the nut will stretch the threads and degrade the fasteners ability to retain

the tooth.

24. Once all pockets and teeth are torqued properly start the machine engine and engage the wheel.

25. Ensure there are no noises emanating from the upgrade installation.

Figure 1.12


Upgrade Assembly Diagram


Split Taper Bushing Removal & Installation Instructions

Warning: Use of Anti-Seize lubricant on tapered cone surfaces or on bolt threads when

mounting may result in damage to sheaves. This voids all manufacturers’ warranties.

1. To Remove From Shaft:

a. Remove capscrews and insert them into tapped holes in bushing flange. (Figure 4.1)

b. Tighten progressively until bushing disengages.

c. Remove assembly from shaft.

2. Installation Instructions:

a. Wipe bushing barrel, bushing bore and shaft clean with a soft dry cloth. Remove paint & other foreign material from bore of mating part. Do not lubricate bushing, bore of mating part, shaft or capscrews.

b. Put bushing loosely into hub. Start capscrews by hand, turning them just enough to engage threads. Do not use a wrench at this time.

c. Slide assembly onto shaft. Line up drive components.

d. Tighten capscrews progressively with a torque wrench until each has been tightened to correct torque. (Table 1.1)

Bolt Torque Table

Bushing

Type

Cap Screw

Size

Wrench

Torque

in./lbs.

P 5/16 - 18 192

Q 3/8 - 16 348

SK 5/16 - 18 180

SF 3/8 - 16 360

Table 1.1

Figure 4.1 (Bushing Only Pictured)

Tapped Holes


GREENTEETH™ GUARANTEE

NEW SETUPS AND FIRST TIME CUSTOMERS:

If you purchase a Greenteeth® setup and are not completely satisfied with its performance, please

contact Green Manufacturing at 800.473.3683 to request a return authorization within 30 days of

purchase date for a product refund or exchange.

PRODUCT QUALITY:

We strive to provide exceptional quality product. Our products undergo a stringent quality control

process, however if you feel that there is an issue with the quality of your product, please contact Green

Manufacturing at 800.473.3683 immediately. We will accept unused parts for return or exchange for up

to 30 days from the date of purchase with proof of purchase included with the return.

Greenteeth® is proudly manufactured in the USA by Green Manufacturing, Inc.

Green Manufacturing, Inc. 9650 Packard Rd

Morenci, MI 49256 Phone 800.473.3683 • Fax 517.458.1550


MATERIAL SAFETY DATA SHEET

I - PRODUCT IDENTIFICATION

Trade Name: Tungsten Carbide Chemical Family: Refractory Metal Alloy

Chemical Formula: WC CAS#: 12070-12-1

II - HAZARDOUS INGREDIENTS

Hazardous Components % OSHA/PEL ACGIH/TLV Sec. 302 Sec. 304 Sec. 313

Tungsten Carbide 0-100 N/E N/E No No No

Tungsten compounds 0-100 5 mg/m3 C - 1 0 mg/m3 No No No

HM IS Ratings (0-4): Health: 3 Flammability: 0 Reactivity: 0

HM IS Protective Equipment: H: glasses, gloves, clothing, combo respirator

III - PHYSICAL DATA

Boiling Point: 6000 oC Melting Point: 2820 - 2940 oC

Evaporation Rate: N/A % Volatiles: N/A

Solubility in H2O: Insoluble Vapor Pressure: N/A

Vapor Density: N/E Specific Gravity: 13.6 gm/cc at 18 oC

Appearance and Odor: Grey to black powder, odorless Molecular Weight: 195.86

IV - FIRE AND EXPLOSION HAZARDS DATA

Flash Point: N/A Flammability: Non-Flammable

Explosive Limits: Lower: N/A Upper: N/A

Extinguishing Media: Use suitable extinguishing media for surrounding materials and type of fire.

Special Fire Fighting Procedures: Firefighters must wear full face, self-contained breathing apparatus with full

protective clothing to prevent contact with skin and eyes. Fumes from fire are hazardous. Isolate runoff to prevent

environmental pollution.

Unusual Hazard: Dusts may present a fire or explosion hazard under rare favoring conditions of particle size,

dispersion, and strong ignition source. However, this is not expected to be a problem under normal handling

conditions.

V - HEALTH HAZARD INFORMATION

Routes of Entry: Inhalation, ingestion, skin or eye contact (for dusts, mists, powder, and fume).

Effects of Overexposure: Industrially tungsten does not constitute an important health hazard. Expo sure is related

chiefly to the dust arising out of the crushing and milling operations. Chronic inhalation of the dust may cause lung

damage in humans. Heavy exposure to the dust or the large amounts of the soluble compounds produces changes

in body weight, behavior, blood cells, choline esterase activity and sperm in experimental animals.

Acute Effects:

Inhalation: Toxic by inhalation. May cause irritation to the mucous membranes, coughing, dyspnea, soreness in

the chest, weight loss, hemoptysis, bronchitis, asthma, pulmonary fibrosis and radiological changes in the lungs.

Ingestion: May cause irritation to the gastrointestinal tract and diarrhea.

Skin: May cause irritation.

Eye: May cause irritation.

Chronic Effects:

Inhalation: May cause damage to the lungs.

Ingestion: No chronic health effects recorded.

Skin: May cause dermatitis, sensitization and eczema.

Eye: May cause conjunctivitis.

Medical Conditions Generally Aggravated by Exposure: Pre-existing respiratory and skin disorders.


Target Organs: May affect the respiratory system.

Carcinogenicity: NTP: No IARC: No OSHA: No

EMERGENCY AND FIRST AID PROCEDURES:

INHALATION: Remove victim to fresh air. Keep warm and quiet, give oxygen if breathing is difficult and seek

medical attention.

INGESTION: If conscious, give 1-2 glasses of milk or water and induce vomiting (Never induce vomiting or give

anything by mouth to an unconscious person). Seek medical attention.

SKIN: Remove contaminated clothing from affected area, brush material off skin. Wash affected area with mild

soap and water. Seek medical attention if symptoms persist.

EYE: Flush eyes with lukewarm water, lifting upper and lower eyelids, for at least 15 minutes. Seek medical

attention if symptoms persist.

VI - REACTIVITY DATA

Stability: Stable

Conditions to Avoid: None

Incompatibility (Material to Avoid): Chlorine, fluorine, nitrogen dioxide, nitrous oxide, iodine pentafluoride and

lead oxide.

Hazardous Decomposition Products: None recorded.

Hazardous Polymerization: Will not occur

VII - SPILL OR LEAK PROCEDURES

Steps to Be Taken in Case Material Is Released or Spilled: Wear appropriate respiratory and protective equipment

specified in Section VIII. Isolate spill area and provide ventilation. Vacuum up spill using a high efficiency

particulate absolute (HEPA) air filter and place in a closed container for proper disposal. Take care not to raise

dust.

Waste Disposal Method: Dispose of in accordance with all local, state, and federal regulations.

VIII - SPECIAL PROTECTION INFORMATION

Respiratory Protection: NIOSH approved dust, mist, and vapor cartridge respirator.

Ventilation: Use local exhaust ventilation which is adequate to limit personal exposure to airborne dust levels

which do not exceed the appropriate PEL or TLV. If such equipment is not available, use respiratory protection as

specified above.

Protective Gloves: Rubber gloves.

Eye Protection: Safety glasses.

Other Protective Clothing or Equipment: Protective gear suitable to prevent contamination.

IX - SPECIAL PRECAUTIONS

Precautions to Be Taken in Handling and Storage: Store in a tightly sealed container in a cool, dry, well-ventilated

area. Wash thoroughly after handling.

Other Precautions: Implement engineering and work practice controls to reduce and maintain concentration of

exposure at low levels. Use good housekeeping and sanitation practices. Do not use tobacco or food in work area.

Wash thoroughly before eating or smoking. Do not blow dust off clothing or skin with compressed air.

The above information is believed to be correct, but does not purport to be all inclusive and shall be used only as a

guide. Green Manufacturing, Inc. shall not be held liable for any damage resulting from handling or from contact

with the above product.

Rayco 1620, 1625, 1631 & 1635 Upgrade Wheel Assembly .pdf©2015 Green Manufacturing, Inc. 1 Read...

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